Insulating wall panels for building construction and related methods

ABSTRACT

Wall panels for building construction may include a corrugated sheet including a first series of peaks on a first side of the corrugated sheet configured for positioning to face a room interior. The corrugated sheet may also include a second series of peaks on a second, opposite side of the corrugated sheet configured for positioning to face a room exterior. A radiant barrier including a material reflective to heat may be secured only to the second series of peaks. The corrugated sheet may form pockets of air between the radiant barrier and the corrugated sheet.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/193,397, filed Nov. 16, 2018, now U.S. Pat. No. 10,837,174, issuedNov. 17, 2020, which claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Patent Application Ser. No. 62/674,161, filed May 21, 2018,the disclosure of each of which is hereby incorporated herein in itsentirety by this reference.

FIELD

This disclosure relates generally to insulating wall panels for buildingconstruction. More specifically, disclosed embodiments relate toinsulating wall panels that may better inhibit heat transfer, reducecost, and enable easier installation.

BACKGROUND

Drywall is a commonly used building material in building construction,particularly for internal walls. For example, internal walls may bebuilt by forming a wood frame, securing panels of drywall to the woodframe (e.g., using screws), and applying joint tape and/or jointcompound to the joints between adjacent panels of drywall to reinforcethe drywall and form smooth surfaces and corners. Insulation againstconductive and convective heat may be provided, for example, by placingfoam or fiberglass in the spaces between wood frame members on a side ofthe drywall opposite the interior. Radiant insulation in the form of athin sheet of heat-reflective, metal material may also be provided,which may be accomplished by adhering a sheet of radiant insulationdirectly to the surface of the drywall that does not face the interior.

BRIEF DESCRIPTION OF THE DRAWINGS

While this disclosure concludes with claims particularly pointing outand distinctly claiming specific embodiments, various features andadvantages of embodiments within the scope of this disclosure may bemore readily ascertained from the following description when read inconjunction with the accompanying drawings, in which:

FIG. 1 is a partial-cutaway perspective view of a wall panel forbuilding construction;

FIG. 2 is a partial-cutaway perspective view of another embodiment of awall panel for building construction;

FIG. 3 is a partial-cutaway perspective view of still another embodimentof a wall panel for building construction;

FIG. 4 is a schematic side view of a stage in a method of making thewall panel of FIG. 1;

FIG. 5 is a cross-sectional top view of the wall panel of FIG. 1installed in a building;

FIG. 6 is a cross-sectional side view of a portion of a laminate productfor use with wall panels in accordance with this disclosure;

FIG. 7 is a cross-sectional side view of a portion of another embodimentof a wall panel for building construction;

FIG. 8 is a cross-sectional side view of a portion of still anotherembodiment of a wall panel for building construction; and

FIG. 9 is a cross-sectional side view of a portion of yet anotherembodiment of a wall panel for building construction.

DETAILED DESCRIPTION

The illustrations presented in this disclosure are not meant to beactual views of any particular wall panel or component thereof, but aremerely idealized representations employed to describe illustrativeembodiments. Thus, the drawings are not necessarily to scale.

Disclosed embodiments relate generally to insulating wall panels thatmay better inhibit heat transfer, reduce cost, and enable easierinstallation. More specifically, disclosed are embodiments of wallpanels for building construction that may include a panel of drywallmaterial, a radiant barrier, and a corrugated sheet interposed betweenthe panel of drywall material and the radiant barrier, the corrugatedsheet configured to provide an air gap between the panel of drywallmaterial and the radiant barrier without requiring complicated andexpensive formation and installation techniques.

As used herein, the terms “substantially” and “about” in reference to agiven parameter, property, or condition means and includes to a degreethat one of ordinary skill in the art would understand that the givenparameter, property, or condition is met with a degree of variance, suchas within acceptable manufacturing tolerances. For example, a parameterthat is substantially or about a specified value may be at least about90% the specified value, at least about 95% the specified value, atleast about 99% the specified value, or even at least about 99.9% thespecified value.

As used herein, spatially relative terms, such as “upper,” “lower,”“bottom,” and “top,” are for ease of description in identifying oneelement's relationship to another element, as illustrated in thefigures. Unless otherwise specified, the spatially relative terms areintended to encompass different orientations of the elements in additionto the orientation depicted in the figures. Thus, the term “upper” canencompass elements above, below, to the left of, or to the right ofother elements, depending on the orientation of an assembly. Theassembly may be otherwise oriented (rotated ninety degrees, inverted,etc.) and the spatially relative descriptors used herein interpretedaccordingly.

As used herein, the term “corrugated” means and includes shapes havingalternate ridges and grooves. For example, structures that arecorrugated may include alternating rows of ridges and grooves oralternating dimples and protrusions in an array, at least one pair ofwhich may form a cross-section having a waving shape.

FIG. 1 is a partial-cutaway perspective view of a wall panel 100 forbuilding construction. The wall panel 100 may include a panel 102 ofdrywall material. The panel 102 may include a room-interior-facingsurface 104 positioned and configured to face a room's interior when thepanel 102 is installed as part of a wall of the room. The panel 102 mayinclude a room-exterior-facing surface 106 located on an opposite sideof the panel 102 from the room-interior-facing surface 104, theroom-exterior-facing surface 106 positioned and configured to face aroom's exterior when the panel 102 is installed as part of a wall of theroom. The room-interior-facing surface 104 of the panel 102 may bepositioned to form a closest surface of the panel 102 relative to theroom's interior when the panel 102 is installed as part of a wall of theroom. The drywall material of the panel 102 may include, for example,gypsum (i.e., calcium sulfate dehydrate), which may be supported betweensheets of facer and backer paper. In other embodiments, the panel 102may include other building materials, such as, for example, woodpaneling, ceramic tile, or stone.

The wall panel 100 may include a radiant barrier 108 including amaterial reflective to at least heat located proximate to theroom-exterior-facing surface 106. More specifically, the radiant barrier108 may be located on a side of the panel 102 of drywall materialopposite the room-interior-facing surface 104. The radiant barrier 108may be configured to inhibit the effect of radiant heat on thetemperature of the room's interior when the wall panel 100 is installedas part of a wall of the room. The radiant barrier 108 may form arearmost surface (i.e., a most exterior portion relative to the interiorof a room) of the wall panel 100 on a side of the panel 102 of drywallmaterial facing the room-exterior-facing surface 106. The radiantbarrier 108 may include, for example, a sheet or foil of thermallyreflective material. More specifically, the radiant barrier 108 mayinclude, for example, a foil of aluminum material having a thermally andoptically reflective surface finish.

A corrugated sheet 110 may be interposed between the panel 102 ofdrywall material and the radiant barrier 108, forming pockets 112 of airbetween the panel 102 of drywall material and portions of the corrugatedsheet 110 and between the radiant barrier 108 and other portions of thecorrugated sheet 110. For example, the corrugated sheet 110 may includea first series of peaks 114 and a corresponding first series of troughs116 located proximate to the room-exterior-facing surface 106 of thepanel 102 of drywall material. The first series of peaks 114 may formlines 118 of contact between the corrugated sheet 110 and thenext-closest component of the wall panel 100, which in the embodiment ofFIG. 1 is the panel 102 of drywall material, and the space defined bythe surface of that component facing the corrugated sheet 110, which isthe room-exterior-facing surface 106 in FIG. 1, and the surfaces of thecorrugated sheet 110 extending from the first series of peaks 114 to thefirst series of troughs 116 may form air gaps to provide the pockets112. The corrugated sheet 110 may further include a second series ofpeaks 120 and a corresponding second series of troughs 122 locatedproximate to the radiant barrier 108. The second series of peaks 120 mayform lines 124 of contact between the corrugated sheet 110 and thenext-closest component of the wall panel 100, which in the embodiment ofFIG. 1 is the radiant barrier 108, and the space defined by the surfaceof that component facing the corrugated sheet 110, which is the surface126 of the radiant barrier 108 facing the panel 102 of drywall materialin FIG. 1, and the surfaces of the corrugated sheet extending from thesecond series of peaks 120 to the second series of troughs 122 may formair gaps to provide additional pockets 112.

The corrugated sheet 110 may have an at least substantially sinusoidalshape when viewed in at least one cross-section at least substantiallyperpendicular to the room-interior-facing surface 104 and theroom-exterior-facing surface 106 of the panel 102 of drywall material.For example, a slope of the corrugated sheet 110 as the corrugated sheet110 transitions between the first series of peaks 114 and the firstseries of troughs 116, and as the corrugated sheet 110 transitionsbetween the second series of peaks 120 and the second series of troughs122 may vary at least substantially continuously, providing a smooth,rounded, arcing wave shape at least substantially resembling a sinewave. The corrugated sheet 110 may include, for example, a cardboardmaterial. More specifically, the corrugated sheet 110 may be of the typeand shape employed between panels of planar cardboard material forcardboard shipping boxes.

The wall panel 100 may include an adhesive material 128 located betweenthe panel 102 of drywall material and the corrugated sheet 110 andbetween the radiant barrier 108 and the corrugated sheet 110. Theadhesive material 128 may secure the corrugated sheet 110 to the panel102 of drywall material and may secure the radiant barrier 108 to thecorrugated sheet 110. For example, the radiant barrier 108 may bedirectly adhered to the corrugated sheet 110 and the corrugated sheet110 may be directly adhered to the panel 102 of drywall material by theadhesive material 128 in embodiments, such as that shown in FIG. 1,where the corrugated sheet 110 is directly adjacent to, and in contactwith, each of the panel 102 of drywall material and the radiant barrier108. More specifically, the adhesive material 128 may be located only onthe first series of peaks 114 of the corrugated sheet 110 facing theroom-exterior-facing surface 106 and on the second series of peaks 120of the corrugated sheet 110 facing the radiant barrier 108. The adhesivematerial 128 may include, for example, a sticky wax material.

A distance D between the room-exterior-facing surface 106 of the panel102 of drywall material and the surface 126 of the radiant barrier 108facing the room-exterior-facing surface 106 of the panel 102 of drywallmaterial, as formed by the corrugated sheet 110, may be, for example,between about 1/32 inch and about ¼ inch. More specifically, thedistance D between the room-exterior-facing surface 106 of the panel 102of drywall material and the surface 126 of the radiant barrier 108facing the room-exterior-facing surface 106 of the panel 102 of drywallmaterial may be, for example, between about 1/16 inch and about ⅛ inch(e.g., about 1/16 inch).

By spacing the panel 102 of drywall material and the radiant barrier 108from one another by a distance D utilizing the corrugated sheet 110 toform the pockets 112 of air between the panel 102 of drywall materialand the corrugated sheet 110 and between the corrugated sheet 110 andthe radiant barrier 108, the wall panel 100 may better insulate againstthe various potential sources of heat transfer than simply directlyadhering the radiant barrier 108 to the room-exterior-facing surface 106of the wall panel 100. For example, the pockets 112 of air, and thebarriers formed by the corrugated sheet 110, may better insulate againstheat transfer by conduction and convection, while the radiant barrier108 may better insulate against heat transfer by radiation.

FIG. 2 is a partial-cutaway perspective view of another embodiment of awall panel 130 for building construction. The corrugated sheet 132 shownin FIG. 2 may have an at least substantially triangle wave shape whenviewed in at least one cross-section at least substantiallyperpendicular to the room-interior-facing surface 104 and theroom-exterior-facing surface 106 of the panel 102 of drywall material.For example, the corrugated sheet 132 may include at least substantiallyplanar sections 134 extending between the first series of peaks 114 andthe first series of troughs 116, and between the second series of peaks120 and the second series of troughs 122, which may for at leastsubstantially linear intersections between the at least substantiallyplanar sections 134, forming a sawtooth-like, ridged series of spikesresembling a triangle wave.

In some embodiments, such as that shown in FIG. 2, the wall panel 130may include additional components interposed between the panel 102 ofdrywall material and the corrugated sheet 132, between the corrugatedsheet 132 and the radiant barrier 108, or between the panel 102 ofdrywall material and the corrugated sheet 132 and between the corrugatedsheet 132 and the radiant barrier 108. For example, the wall panel 130may include a planar sheet 136 interposed between the corrugated sheet132 and the panel 102 of drywall material. The planar sheet 136 may bedirectly adhered to the corrugated sheet 132 and to the panel 102 ofdrywall material by the adhesive material 128. As another example, thewall panel 130 may include an overlying planar sheet 138 interposedbetween the corrugated sheet 132 and the radiant barrier 108. Theoverlying planar sheet 138 may be directly adhered to the corrugatedsheet 132 and to the radiant barrier 108 by the adhesive material 128.As still another example, the wall panel 130 may include the planarsheet 136 interposed between the corrugated sheet 132 and the panel 102of drywall material and the other overlying planar sheet 138 interposedbetween the corrugated sheet 132 and the radiant barrier 108. Morespecifically, the corrugated sheet 132 may be provided in the form of acomplete panel of cardboard, including the planar sheet 136 and theother overlying planar sheet 138 on opposite sides of the corrugatedsheet 132, which planar sheet 136 and other overlying planar sheet 138may, in turn, be adhered to the panel 102 of drywall material and theradiant barrier 108 to form the wall panel 130.

FIG. 3 is a partial-cutaway perspective view of still another embodimentof a wall panel 140 for building construction. The wall panel 140 mayinclude, for example, at least one other corrugated sheet 142 located ona side of the radiant barrier 108 opposite the panel 102 of drywallmaterial. For example, the other corrugated sheet 142 may be secured tothe radiant barrier 108 by the adhesive material 128. The corrugatedsheet 110 may include, for example, another first series of peaks 144and another corresponding first series of troughs 146 located proximateto the radiant barrier 108. The other first series of peaks 144 may formlines 148 of contact between the other corrugated sheet 142 and thenext-closest component of the wall panel 140, which in the embodiment ofFIG. 3 is the radiant barrier 108, and the space defined by the surfaceof that component facing the other corrugated sheet 142, which is therearmost surface 150 of the radiant barrier 108 in FIG. 3, and thesurfaces of the other corrugated sheet 142 extending from the otherfirst series of peaks 144 to the other first series of troughs 146 mayform air gaps to provide still other pockets 152 of air. The othercorrugated sheet 142 may form a rearmost surface (i.e., a most exteriorportion relative to the interior of a room) of the wall panel 140 on aside of the panel 102 of drywall material facing theroom-exterior-facing surface 106.

The lines 148 of contact between the other first series of peaks 144 ofthe other corrugated sheet 142 and the radiant barrier 108 may extend,for example, in a direction at least substantially perpendicular to thelines 118 of contact between the corrugated sheet 110 and the panel 102of drywall material. In other embodiments, the lines 148 of contactbetween the other first series of peaks 144 of the other corrugatedsheet 142 and the radiant barrier 108 may extend, for example, in adirection parallel, or oblique, to the lines 118 of contact between thecorrugated sheet 110 and the panel 102 of drywall material.

Although the corrugated sheet 110 and the other corrugated sheet 142 aredepicted in FIG. 3 as having an at least substantially sinusoidalcross-sectional shape, like the corrugated sheet 110 of FIG. 1, thecorrugated sheet 110, the other corrugated sheet 142, or the corrugatedsheet 110 and the other corrugated sheet 142 may have an at leastsubstantially triangle wave cross-sectional shape, like the corrugatedsheet 132 of FIG. 2. And although the corrugated sheet 110 and the othercorrugated sheet 142 are depicted in FIG. 3 as being in direct contactwith the panel 102 of drywall material and the radiant barrier 108, likethe corrugated sheet 110 of FIG. 1, the corrugated sheet 110, the othercorrugated sheet 142, or the corrugated sheet 110 and the othercorrugated sheet 142 may be in direct contact with one or more planarsheets 136, 138 (see FIG. 2) interposed between the corrugated sheet 110and one or both of the panel 102 of drywall material and the radiantbarrier and/or located on one or both sides of the other corrugatedsheet 142.

FIG. 4 is a schematic side view of a stage in a method of making thewall panel 100 of FIG. 1. Before securing the corrugated sheet 110 tothe panel 102 of drywall material and the radiant barrier 108, theadhesive material 128 may be placed on the corrugated sheet 110. Forexample, the corrugated sheet 110 may be moved past an adhesive-applyingdevice, which may place the adhesive material 128 on the corrugatedsheet 110, and the adhesive material 128 may be used to secure thecorrugated sheet 110 to the panel 102 of drywall material and theradiant barrier 108. More specifically, the corrugated sheet 110 may bemoved past rollers 154 having the adhesive material 128 coated on theoutside surfaces of the rollers 154. As the first series of peaks 114and the second series of peaks 120 of the corrugated sheet 110 come intocontact with the rollers 154, the rollers 154 may rotate and deposit theadhesive material 128 onto the first series of peaks 114 and the secondseries of peaks 120. Once the adhesive material 128 has been applied,the adhesive material 128 located on the first series of peaks 114 maybe brought into contact with the panel 102 of drywall material and theadhesive material 128 located on the second series of peaks 120 may bebrought into contact with the radiant barrier 108 and cured or permittedto cure to adhere the corrugated sheet 110 to the panel 102 of drywallmaterial and the radiant barrier 108. In embodiments where thecorrugated sheet 110 is provided with one or more planar sheets 136, 138(see FIG. 2), the adhesive material 128 may be placed on the planarsheet or sheets 136, 138 (see FIG. 2), rather than on the correspondingfirst series of peaks 114 or second series of peaks 120.

Because making the wall panel 100 may only require placement of adhesivematerial 128 and attachment of the various components to one another,the process may be simple, susceptible to automation, and low-cost. As aresult, the resulting wall panels 100 may remain a cost-competitiveoption for providing insulation when constructing a building.

FIG. 5 is a cross-sectional top view of the wall panel 100 of FIG. 1installed in a building. When installing the wall panel 100, a wallframe 156 for supporting the wall panel 100 may be provided. The wallframe 156 may be formed from wooden members, and may link the wall panel100 to the supporting structure for the building (e.g., may transmit theloads of the wall panel 100 to the foundation, building frame, or othersupport structure). The wall frame 156 may include studs 158 spaced atregular intervals from one another. The studs 158 may form a wall space160 into which other insulating material 162 may be placed beforeinstalling the wall panel 100. For example, insulating foam orfiberglass insulation may be positioned in the wall space 160 to furtherinhibit heat transfer due to conduction and convection.

The wall panel 100 may be brought proximate to the studs 158, with theroom-exterior-facing surface 106 facing the studs 158. An exterior-mostsurface of the wall panel 100 may be brought into contact with the studs158. For example, the rearmost surface 150 of the radiant barrier 108may be contacted to the studs 158 in embodiments where the radiantbarrier 108 is the component of the wall panel 100 farthest to theexterior. In other embodiments, the other corrugated sheet 142 (see FIG.3) or a planar sheet 136, 138 (see FIG. 2) may be contacted to the studs158.

The wall panel 100 may be secured to the studs 158 to support the wallpanel 100 on the wall frame 156. For example, screws 164 may be insertedthrough the panel 102 of drywall material, through the corrugated sheet110, through the radiant barrier 108, and through any other componentsof the wall panel 100, into the studs 158 to secure the wall panel 100to the wall frame 156. Tightening the screws 164 may, for example,compress the corrugated sheet 110, although the pockets 112 of air mayremain between the panel 102 of drywall material and the corrugatedsheet 110 and between the corrugated sheet 110 and the radiant barrier108 along a majority of the room-exterior-facing surface 106.

Because installing the wall panel 100 may not require any specializedinstallation techniques, particularly when compared to installingconventional panels of drywall material or such panels with radiantbarriers adhered directly to the panels of drywall material, the wallpanels 100 may not significantly increase the time and cost forconstructing walls. With this and other advantages discussed in thisapplication, as well as other advantages not explicitly mentioned, wallpanels 100, 130 (see FIG. 2), 140 (see FIG. 3) in accordance with thisdisclosure may better inhibit heat transfer, particularly due toconduction and convection, without significantly increasing the cost orcomplexity associated with making and installing the wall panels 100,130 (see FIG. 2), 140 (see FIG. 3).

FIG. 6 is a cross-sectional side view of a portion of a laminate product170 for use with wall panels in accordance with this disclosure. Thelaminate product 170 may include the corrugated sheet 110, which may beconfigured as an undulating lamina of cardboard material. Optionally,the laminate product 170 may include one or more planar sheets 136 and138 located on opposite sides of the corrugated sheet 110, which planarsheets 136 and 138 may be configured as at least substantially planarlamina of cardboard material. Any planar sheets 136 and 138 included inthe laminate product 170 may be secured, directly or indirectly, to thecorrugated sheet 110.

The laminate product 170 may include one or more radiant barrierssecured to corresponding surfaces of one or more of the corrugated sheet110, an optional underlying planar sheet 136, and an optional overlyingplanar sheet 138 of the laminate product 170. For example, the laminateproduct 170 may include the radiant barrier 108 located on a side of theoverlying planar sheet 138 opposite the corrugated sheet 110. Morespecifically, the radiant barrier 108 may be affixed to anexterior-facing surface 172 of the overlying planar sheet 138 by anadhesive material 128. The radiant barrier 108 may form an exterior-mostcomponent of the laminate product 170.

In addition to, or instead of, the radiant barrier 108 located closestto an exterior of a room in which a wall panel including the laminateproduct 170 may be installed, the laminate product 170 may include aradiant barrier 174 located on a side of the corrugated sheet 110opposite the optional underlying planar sheet 136. In embodiments wherethe laminate product 170 includes the optional overlying planar sheet138, the radiant barrier 174 may be interposed between the corrugatedsheet 110 and the overlying planar sheet 138. More specifically, theradiant barrier 174 may be affixed to an interior-facing surface 176 ofthe overlying planar sheet 138 and to the second series of peaks 120 ofthe corrugated sheet 110 or a second series of peaks 183 of a corrugatedradiant barrier 180 secured to an exterior-facing surface 182 of thecorrugated sheet 110 by an adhesive material 128.

In addition to, or instead of, the radiant barrier 108 located at theexterior, the radiant barrier 174 located between the corrugated sheet110 and the overlying planar sheet 138, or some combination orsubcombination thereof, the laminate product 170 may include acorrugated radiant barrier 180 located adjacent to the corrugated sheet110. The corrugated radiant barrier 180 may be located on anexterior-facing surface 182 of the corrugated sheet 110 or on aninterior-facing surface 184 of the corrugated sheet 110. The corrugatedradiant barrier 180 may undulate, following the waving patterns of thecorrugated sheet 110 and forming its own first series of peaks 178 andcorresponding first series of troughs 181 (as shown on the left-handside of FIG. 6) or its own second series of peaks 183 and correspondingsecond series of troughs 185 (as shown on the right-hand side of FIG. 6)covering those of the corrugated sheet 110. More specifically, thecorrugated radiant barrier 180 may cover, and be affixed to, the firstseries of peaks 114 and corresponding first series of troughs 116forming the interior-facing surface 188 of the corrugated sheet 110, ormay cover, and be affixed to, the second series of peaks 120 andcorresponding second series of troughs 122 forming the exterior-facingsurface 182 of the corrugated sheet 110, or both by an adhesivematerial.

In addition to, or instead of, the radiant barrier 108 located at theexterior, the radiant barrier 174 located between the corrugated sheet110 and the overlying planar sheet 138, the corrugated radiant barrier180 located on one or both major surfaces 186 and 188 of the corrugatedsheet 110, or some combination or subcombination thereof, the laminateproduct 170 may include a first radiant barrier 190 located on a side ofthe corrugated sheet 110 opposite the optional overlying planar sheet138. In embodiments where the laminate product 170 includes the optionalunderlying planar sheet 136, the first radiant barrier 190 may beinterposed between the corrugated sheet 110 and the underlying planarsheet 136. More specifically, the first radiant barrier 190 may beaffixed to an exterior-facing surface 192 of the underlying planar sheet136 and to the first series of troughs 116 of the corrugated sheet 110or the first series of troughs 181 of a corrugated radiant barrier 180secured to an interior-facing surface 188 of the corrugated sheet 110 byan adhesive material 128.

In addition to, or instead of, the radiant barrier 108 located at theexterior, the radiant barrier 174 located between the corrugated sheet110 and the overlying planar sheet 138, the corrugated radiant barrier180 located on one or both major surfaces 186 and 188 of the corrugatedsheet 110, the first radiant barrier 190 located between the corrugatedsheet 110 and the underlying planar sheet 136, or some combination orsubcombination thereof, the laminate product 170 may include aninterior-most radiant barrier 194 located on a side of the underlyingplanar sheet 136 opposite the corrugated sheet 110. More specifically,the interior-most radiant barrier 194 may be affixed to aninterior-facing surface 196 of the underlying planar sheet 136 by anadhesive material 128. The interior-most radiant barrier 194 may form aninterior-most component of the laminate product 170.

Laminate products in accordance with this disclosure, and wall panelsresulting from affixing the laminate products to a panel of drywallmaterial, may include any one, any combination, or any subcombination ofthe radiant barriers, their positioning and manner of affixation,described previously in connection with FIG. 6. Certain, specificconfigurations for wall panels, and their associated laminate productsincluding radiant barriers, are discussed in greater detail inconnection with FIGS. 7 through 9.

FIG. 7 is a cross-sectional side view of a portion of another embodimentof a wall panel 198 for building construction. The wall panel 198 mayinclude a panel 102 of drywall material and a laminate product 170affixed to a room-exterior-facing surface 106 of the panel 102 ofdrywall material. The laminate product 170 may include an interior-mostradiant barrier 194 located adjacent to, be in contact with, andoptionally be adhered to the panel 102 of drywall material. Theinterior-most radiant barrier 194 may form an interior-most component ofthe laminate product 170. The laminate product 170 may include a planarsheet 136 located on a side of the interior-most radiant barrier 194opposite the panel 102 of drywall material, such that the interior-mostradiant barrier 194 may be interposed between the planar sheet 136 andthe panel 102 of drywall material. The interior-most radiant barrier 194may be, for example, affixed to each of the planar sheet 136 and thepanel 102 of drywall material by an adhesive material 128.

A corrugated sheet 110 may be affixed to the planar sheet 136 on a sideof the planar sheet 136 opposite the interior-most radiant barrier 194,and another overlying planar sheet 138 may be affixed to the corrugatedsheet 110 on a side of the corrugated sheet 110 opposite the firstplanar sheet 136. In other words, the corrugated sheet 110 may beinterposed between the planar sheets 136 and 138, each of which sheets110, 136, and 138 may include a cardboard material. Another radiantbarrier 108 may be affixed to the overlying planar sheet 138 locateddistal from the panel 102 of drywall material on a side of the overlyingplanar sheet 138 opposite the panel 102 of drywall material, such thatthe radiant barrier 108 may form an exterior-most component of thelaminate product 170 and of the wall panel 198.

FIG. 8 is a cross-sectional side view of a portion of still anotherembodiment of a wall panel 200 for building construction. The wall panel200 may include a panel 102 of drywall material and a laminate product170 affixed to a room-exterior-facing surface 106 of the panel 102 ofdrywall material. The laminate product 170 may include a planar sheet136 adjacent to, in contact with, and optionally adhered to the panel102 of drywall material. The planar sheet 136 may form an interior-mostcomponent of the laminate product 170. The laminate product 170 mayinclude a first radiant barrier 190 located on a side of the planarsheet 136 opposite the panel 102 of drywall material, such that theplanar sheet 136 may be interposed between the first radiant barrier 190and the panel 102 of drywall material. The planar sheet 136 may be, forexample, affixed to each of the first radiant barrier 190 and the panel102 of drywall material by an adhesive material 128.

A corrugated sheet 110 may be affixed to the first radiant barrier 190on a side of the first radiant barrier 190 opposite the planar sheet136. Another radiant barrier 174 may be affixed to the corrugated sheet110 on a side of the corrugated sheet 110 opposite the first radiantbarrier 190. In other words, the corrugated sheet 110 may be interposedbetween the radiant barriers 174 and 190. Another overlying planar sheet138 may be affixed to the radiant barrier 174 located distal from thepanel 102 of drywall material on a side of the radiant barrier 174opposite the panel 102 of drywall material, such that the overlyingplanar sheet 138 may form an exterior-most component of the laminateproduct 170 and of the wall panel 198.

Though FIGS. 7 and 8 have depicted the laminate product 170 as includingradiant barriers 108 and 194 at the innermost and outermost extents ofthe laminate product 170 or as including radiant barriers 174 and 190located immediately adjacent to the corrugated sheet 110, othercombinations of the different positions for the radiant barriers 108,174, 190, and 194 are contemplated. For example, the laminate product170 may include the exterior-most radiant barrier 108 and the firstradiant barrier 190 adjacent to the corrugated sheet 110 on a side ofthe corrugated sheet 110 proximate to the panel 102 of drywall material.As another example, the laminate product 170 may include theinterior-most radiant barrier 194 and the radiant barrier 174 locatedadjacent to the corrugated sheet 110 on a side of the corrugated sheet110 opposite the panel 102 of drywall material. As yet another example,the laminate product 170 may include any combination of three of theradiant barriers 108, 174, 190, 194.

FIG. 9 is a cross-sectional side view of a portion of yet anotherembodiment of a wall panel 202 for building construction. The wall panel202 may include a panel 102 of drywall material and a laminate product170 affixed to a room-exterior-facing surface 106 of the panel 102 ofdrywall material. The laminate product 170 may include a planar sheet136 adjacent to, in contact with, and optionally adhered to the panel102 of drywall material. The planar sheet 136 may form an interior-mostcomponent of the laminate product 170. The laminate product 170 mayinclude. A corrugated sheet 110 affixed to the planar sheet 136 on aside of the planar sheet 136 opposite the panel 102 of drywall material.

A corrugated radiant barrier 180 may be affixed to the corrugated sheet110 in such a manner that the corrugated radiant barrier 180 mayundulate with the waves of the corrugated sheet 110. The corrugatedradiant barrier 180 may be, for example, affixed to the corrugated sheet110 on a side of the corrugated sheet 110 opposite the panel 102 ofdrywall material by an adhesive material 128. Another overlying planarsheet 138 may be affixed to the corrugated radiant barrier 180 on a sideof the corrugated radiant barrier 180 opposite the first planar sheet136. The planar sheets 136 and 138 may form the outermost components ofthe laminate product 170, with the corrugated sheet and the corrugatedradiant barrier 180 sandwiched therebetween.

Though the corrugated radiant barrier 180 is depicted as being locatedon a specific side of the corrugated sheet 110, and is depicted as beingused without the inclusion of any other radiant barriers secured to, andundulating with, the corrugated sheet 110 or extending in an at leastsubstantially planar manner over one or more surfaces of the planarsheets 136 and 138, the corrugated radiant barrier 180 may be located onthe opposite side of the corrugated sheet 110 proximate to the panel 102of drywall material, another corrugated radiant barrier 180 located onthe opposite side of the corrugated sheet 110 proximate to the panel 102of drywall material may be included, and one or more other radiantbarriers 108, 174, 190, 194 (see FIG. 6) may also be provided.

Additional, nonlimiting embodiments within the scope of this disclosureinclude, but are not limited to, the following:

Embodiment 1

A wall panel for building construction, comprising: a panel of drywallmaterial comprising a room-interior-facing surface and aroom-exterior-facing surface; a radiant barrier comprising a materialreflective to heat located proximate to the room-exterior-facingsurface; and a corrugated sheet interposed between the panel of drywallmaterial and the radiant barrier, the corrugated sheet forming pocketsof air between the panel of drywall material and the corrugated sheetand between the radiant barrier and the corrugated sheet.

Embodiment 2

The wall panel of Embodiment 1, wherein the radiant barrier is directlyadhered to the corrugated sheet and the corrugated sheet is directlyadhered to the panel of drywall material by an adhesive material.

Embodiment 3

The wall panel of Embodiment 2, wherein the adhesive material is locatedonly on peaks of the corrugated sheet facing the room-exterior-facingsurface and on peaks of the corrugated sheet facing the radiant barrier.

Embodiment 4

The wall panel of Embodiment 2 or Embodiment 3, wherein the adhesivematerial comprises a wax material.

Embodiment 5

The wall panel of any one of Embodiment 1, further comprising a planarsheet interposed between the corrugated sheet and the panel of drywallmaterial, the planar sheet directly adhered to the corrugated sheet andto the panel of drywall material by an adhesive material.

Embodiment 6

The wall panel of Embodiment 5, further comprising at least one otherradiant barrier comprising a material reflective to heat adhered to theplanar sheet, the at least one other radiant barrier interposed betweenthe panel of drywall material and the corrugated sheet on at least onecorresponding side of the planar sheet.

Embodiment 7

The wall panel of Embodiment 1, further comprising a planar sheetinterposed between the corrugated sheet and the radiant barrier, theplanar sheet directly adhered to the corrugated sheet and to the radiantbarrier by an adhesive material.

Embodiment 8

The wall panel of any one of Embodiments 1 through 7, wherein thecorrugated sheet comprises a cardboard material.

Embodiment 9

The wall panel of any one of Embodiments 1 through 8, further comprisinganother corrugated sheet located on a side of the radiant barrieropposite the panel of drywall material, the other corrugated sheetsecured to the radiant barrier by an adhesive material.

Embodiment 10

The wall panel of Embodiment 9, wherein lines of contact between peaksof the corrugated sheet and the panel of drywall material extend atleast substantially perpendicular to lines of contact between the othercorrugated sheet and the radiant barrier.

Embodiment 11

The wall panel of any one of Embodiments 1 through 10, wherein thecorrugated sheet has an at least substantially sinusoidal shape whenviewed in at least one cross-section at least substantiallyperpendicular to the room-interior-facing surface and theroom-exterior-facing surface of the panel of drywall material.

Embodiment 12

The wall panel of any one of Embodiments 1 through 10, wherein thecorrugated sheet has an at least substantially triangle wave shape whenviewed in at least one cross-section at least substantiallyperpendicular to the room-interior-facing surface and theroom-exterior-facing surface of the panel of drywall material.

Embodiment 13

The wall panel of any one of Embodiments 1 through 8, 11, and 12,wherein the radiant barrier forms a rearmost surface of the wall panelon a side of the panel of drywall material facing theroom-exterior-facing surface.

Embodiment 14

The wall panel of any one of Embodiments 1, 2, 4, 8, and 11 through 13,wherein the radiant barrier is affixed to, and undulates with, thecorrugated sheet.

Embodiment 15

A method of making a wall panel for building construction, comprising:placing an adhesive material on a first series of peaks of a corrugatedsheet on a first side of the corrugated sheet; adhering the corrugatedsheet to a panel of drywall material by contacting the first series ofpeaks and the adhesive material to the drywall material; placing theadhesive material on a second series of peaks of the corrugated sheet ona second, opposite side of the corrugated sheet; and adhering thecorrugated sheet to a radiant barrier comprising a reflective materialby contacting the second series of peaks and the adhesive material tothe radiant barrier.

Embodiment 16

The method of Embodiment 15, wherein placing the adhesive material onthe first series of peaks of the corrugated sheet comprises contactingthe first series of peaks to a first roller having the adhesive materialon an exterior surface of the first roller, the first roller located onthe first side of the corrugated sheet, and rotating the first roller asthe corrugated sheet is moved past the first roller and wherein placingthe adhesive material on the second series of peaks of the corrugatedsheet comprises contacting the second series of peaks to a second rollerhaving the adhesive material on an exterior surface of the secondroller, the second roller located on the second, opposite side of thecorrugated sheet, and rotating the second roller as the corrugated sheetis moved past the second roller.

Embodiment 17

A method of installing a wall panel for building construction,comprising: placing a radiant barrier of a wall panel proximate at leastone stud of a wall frame, the radiant barrier comprising a reflectivematerial, the radiant barrier located on a first side of a corrugatedsheet, the wall panel comprising a panel of drywall material adhered toa second, opposite side of the corrugated sheet; and securing the wallpanel to the wall frame by at least one screw extending through thepanel of drywall material, through the corrugated sheet, and through theradiant barrier into the at least one stud.

Embodiment 18

The method of Embodiment 17, further comprising compressing thecorrugated sheet in response to securing the wall panel to the wallframe.

Embodiment 19

The method of Embodiment 17 or Embodiment 18, wherein placing theradiant barrier proximate the at least one stud comprises contacting theradiant barrier directly to the at least one stud.

Embodiment 20

The method of Embodiment 17 or Embodiment 18, wherein the wall panelfurther comprises another corrugated sheet located on a side of theradiant barrier opposite the panel of drywall material and whereinplacing the radiant barrier proximate the at least one stud comprisescontacting the other corrugated sheet directly to the at least one stud.

While certain illustrative embodiments have been described in connectionwith the figures, those of ordinary skill in the art will recognize andappreciate that the scope of this disclosure is not limited to thoseembodiments explicitly shown and described in this disclosure. Rather,many additions, deletions, and modifications to the embodimentsdescribed in this disclosure may be made to produce embodiments withinthe scope of this disclosure, such as those specifically claimed,including legal equivalents. In addition, features from one disclosedembodiment may be combined with features of another disclosed embodimentwhile still being within the scope of this disclosure, as contemplatedby the inventor.

What is claimed is:
 1. A wall panel for building construction,comprising: a corrugated sheet comprising a first series of peaks on afirst side of the corrugated sheet configured for positioning to face aroom interior and a second series of peaks on a second, opposite side ofthe corrugated sheet configured for positioning to face a room exterior;and a radiant barrier comprising a material reflective to heat securedonly to the second series of peaks, the corrugated sheet forming pocketsof air between the radiant barrier and the corrugated sheet; wherein amajority of the radiant barrier is exposed to air on a side configuredfor positioning to face a room interior and the majority of the radiantbarrier is exposed to air on an opposite side configured for positioningto face a room exterior.
 2. The wall panel of claim 1, furthercomprising another corrugated sheet secured to the radiant barrier on aside of the radiant barrier opposite the corrugated sheet, such that theradiant barrier is interposed between the corrugated sheet and the othercorrugated sheet.
 3. The wall panel of claim 2, wherein lines of contactbetween the second series of peaks of the corrugated sheet and theradiant barrier extend at least substantially perpendicular to lines ofcontact between another series of peaks of the other corrugated sheetand the radiant barrier.
 4. The wall panel of claim 1, wherein thecorrugated sheet has an at least substantially sinusoidal shape whenviewed in at least one cross-section.
 5. The wall panel of claim 1,wherein the corrugated sheet has an at least substantially triangle waveshape when viewed in at least one cross-section.
 6. The wall panel ofclaim 1, wherein the radiant barrier forms a rearmost surface of thewall panel on a side of the corrugated sheet for positioning to face aroom exterior.
 7. The wall panel of claim 1, wherein an adhesivematerial adhering the radiant barrier to the second series of peaks islocated only on the second series of peaks.
 8. The wall panel of claim7, wherein the adhesive material comprises a wax material.
 9. The wallpanel of claim 1, wherein the corrugated sheet comprises a cardboardmaterial.
 10. The wall panel for building construction of claim 1,further comprising a panel of drywall material adhered to the firstseries of peaks.